EP2737911B1 - Polyolefindispersionen, Schäume und Schaumstoffe - Google Patents

Polyolefindispersionen, Schäume und Schaumstoffe Download PDF

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EP2737911B1
EP2737911B1 EP13193042.2A EP13193042A EP2737911B1 EP 2737911 B1 EP2737911 B1 EP 2737911B1 EP 13193042 A EP13193042 A EP 13193042A EP 2737911 B1 EP2737911 B1 EP 2737911B1
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Prior art keywords
foam
froth
flame retardant
ethylene
weight
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French (fr)
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EP2737911A3 (de
EP2737911A2 (de
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Bruce A. Menning
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Dow Global Technologies LLC
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Dow Global Technologies LLC
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    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
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    • C08J3/02—Making solutions, dispersions, lattices or gels by other methods than by solution, emulsion or suspension polymerisation techniques
    • C08J3/03—Making solutions, dispersions, lattices or gels by other methods than by solution, emulsion or suspension polymerisation techniques in aqueous media
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L15/00—Chemical aspects of, or use of materials for, bandages, dressings or absorbent pads
    • A61L15/16—Bandages, dressings or absorbent pads for physiological fluids such as urine or blood, e.g. sanitary towels, tampons
    • A61L15/42—Use of materials characterised by their function or physical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • C08K5/16—Nitrogen-containing compounds
    • C08K5/34—Heterocyclic compounds having nitrogen in the ring
    • C08K5/3467—Heterocyclic compounds having nitrogen in the ring having more than two nitrogen atoms in the ring
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    • C08L1/26—Cellulose ethers
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    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
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    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
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    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/10—Homopolymers or copolymers of propene
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    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
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    • C08J2201/00—Foams characterised by the foaming process
    • C08J2201/04—Foams characterised by the foaming process characterised by the elimination of a liquid or solid component, e.g. precipitation, leaching out, evaporation
    • C08J2201/05—Elimination by evaporation or heat degradation of a liquid phase
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    • C08J2205/00—Foams characterised by their properties
    • C08J2205/04—Foams characterised by their properties characterised by the foam pores
    • C08J2205/05—Open cells, i.e. more than 50% of the pores are open
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    • C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
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    • C08L2201/00—Properties
    • C08L2201/02—Flame or fire retardant/resistant
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/24992—Density or compression of components
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3854—Woven fabric with a preformed polymeric film or sheet
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    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/674—Nonwoven fabric with a preformed polymeric film or sheet

Definitions

  • inventions disclosed herein relate to a flame retardant foam.
  • the foam may include a thermoplastic resin and at least one flame retardant, wherein the at least one flame retardant may be from 5 to 70 percent of a total weight of the thermoplastic resin and the at least one flame retardant.
  • embodiments of the polymers when produced in a continuous process, may possess a PDI ranging from about 1.7 to about 8; from about 1.7 to about 3.5 in other embodiments; from about 1.7 to about 2.5 in other embodiments; and from about 1.8 to about 2.5 or from about 1.8 to about 2.1 in yet other embodiments.
  • embodiments of the polymers When produced in a batch or semi-batch process, embodiments of the polymers may possess a PDI ranging from about 1.0 to about 2.9; from about 1.3 to about 2.5 in other embodiments; from about 1.4 to about 2.0 in other embodiments; and from about 1.4 to about 1.8 in yet other embodiments.
  • the foam/fabric sample When tested for horizontal burn performance using ASTM D4986 Standard Test Method for Horizontal Burning Characteristics of Cellular Polymeric Materials, the foam/fabric sample gives a burn length of 3.0 cm after 3 minutes elapsed time and is almost self extinguishing.
  • thermocouple capable of withstanding the test temperature is fixed in direct contact with the back (non-flame) side of the sample.
  • a piece of urethane foam, approximately 1 ⁇ 2" thick is then placed on top of the sample and the thermocouple to provide insulation for a more accurate measurement of back sample temperature.
  • Another widely spaced grid is then placed on the urethane foam to hold the sample flat during the test.
  • a flame source similar to that used in ASTM D4986, is then placed under the sample for a period of 120 seconds.
  • the back surface temperature, as measured by the thermocouple is then recorded versus time. Materials that are good at resisting flame, such as glass non-wovens, but not good at insulating will have a rapid temperature rise in this test.

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  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • General Chemical & Material Sciences (AREA)
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  • Hematology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Animal Behavior & Ethology (AREA)
  • General Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Veterinary Medicine (AREA)
  • Dispersion Chemistry (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Laminated Bodies (AREA)

Claims (15)

  1. Ein Schaumstoff, abgeleitet von einer geschäumten stabilisierten wässrigen Dispersion, beinhaltend:
    (a) ein thermoplastisches Harz, ausgewählt aus einem Ethylenhomopolymer, einem Ethylen/a-Olefin-Copolymer, einem Ethylen/α-Olefin-Multiblock-Mischpolymer, einem Propylenhomopolymer, einem Propylen/α-Olefin-Copolymer, einem Propylen/α-Olefin-Multiblock-Mischpolymer; oder Kombinationen davon;
    (b) Wasser;
    (c) ein schäumendes Tensid;
    (d) ein Gas;
    (e) ein Dispersionsstabilisierungsmittel; und
    (f) mindestens ein Phasenänderungsmaterial oder mindestens einen Flammhemmer.
  2. Schaumstoff gemäß Anspruch 1, wobei mindestens ein Dispersionsstabilisierungsmittel und mindestens ein schäumendes Mittel gleich sind.
  3. Ein Verfahren zum Herstellen eines thermoplastischen Schaumstoffs aus einer stabilisierten wässrigen Dispersion, wobei die stabilisierte wässrige Dispersion Folgendes beinhaltet:
    ein thermoplastisches Harz, ausgewählt aus einem Ethylenhomopolymer, einem Ethylen/α-Olefin-Copolymer, einem Ethylen/α-Olefin-Multiblock-Mischpolymer, einem Propylenhomopolymer, einem Propylen/α-Olefin-Copolymer, einem Propylen/a-Olefin-Multiblock-Mischpolymer; oder Kombinationen davon;
    Wasser; und
    ein Dispersionsstabilisierungsmittel,
    wobei das Verfahren Folgendes beinhaltet:
    Zugeben mindestens eines schäumenden Tensids zu der stabilisierten wässrigen Dispersion, um eine Mischung zu bilden;
    Zugeben eines Phasenänderungsmaterials oder eines Flammhemmers;
    Schäumen der Mischung, um einen Schaum zu erzeugen; und
    Entfernen von mindestens einem Teil des Wassers, um den Schaumstoff zu produzieren;
    wobei der erzeugte Schaumstoff etwa 20 Gewichtsprozent oder weniger Restwasser beinhaltet.
  4. Schaumstoff gemäß Anspruch 1, wobei das mindestens eine Phasenänderungsmaterial 5 bis 70 Prozent eines Gesamtgewichts des thermoplastischen Harzes und des mindestens einen Phasenänderungsmaterials ausmacht.
  5. Schaumstoff gemäß Anspruch 4, wobei das Phasenänderungsmaterial mindestens ein Element, ausgewählt aus einem mikroverkapselten Wachs, einer Fettsäure oder einem Fettsäureester, einem Paraffin, Salzhydriden und Kombinationen davon, beinhaltet.
  6. Schaumstoff gemäß Anspruch 1, wobei der Schaumstoff ein offenzelliger Schaumstoff ist.
  7. Offenzelliger Schaumstoff gemäß Anspruch 6, wobei
    das schäumende Tensid mindestens eines von Alkylcelluloseethern, Hydroxyalkylcelluloseethern, Hydroxyalkylalkylcelluloseethern, Guargummi, Xanthan und Polyoxyethylenharzen mit einem Molekulargewicht von mindestens 20 000 beinhaltet; und
    wobei die geschäumte stabilisierte wässrige Dispersion zu 15 bis 75 Gewichtsprozent Komponente (a), zu 25 bis 75 Gewichtsprozent Komponente (b), zu 0,1 bis 10 Gewichtsprozent Komponente (c), zu 5 bis 50 Gewichtsprozent Komponente (f) beinhaltet, und wobei (d) in einer Menge vorhanden ist, so dass (d) mindestens 10 Prozent des Gesamtvolumens aller in dem Schaum vorhandenen Komponenten ausmacht; und
    wobei Komponente (f) mindestens ein Flammhemmer ist, ausgewählt aus einem anorganischen Salz, einem Intumeszenzmittel, einer halogenierten Verbindung, einer Phosphatverbindung, einer Boratverbindung, einer Melaminverbindung und Kombinationen davon, und 5 bis 70 % eines Gesamtgewichts des thermoplastischen Harzes, des mindestens einen schäumenden Tensids und des mindestens einen Flammhemmers ausmacht.
  8. Schaumstoff gemäß Anspruch 7, wobei die Zellengröße des Großteils der Zellen des Schaumstoffs im Bereich zwischen etwa 5 und etwa 1000 Mikrometer liegt.
  9. Schaumstoff gemäß Anspruch 7, wobei der Schaumstoff eine horizontale Verbrennungslänge von 80 % oder weniger als eine Nicht-Flammhemmer-Kontrollprobe aufweist, gemäß ASTM D4986 Standard Test Method for Horizontal Burning Characteristics of Cellular Polymeric Materials (Prüfverfahren für das Horizontalbrennverhalten von Schaumkunststoffen).
  10. Schaumstoff gemäß Anspruch 7, wobei die Dichte des Schaumstoffs auf einer Trockenbasis zwischen etwa 0,02 g/cm3 und etwa 0,30 g/cm3 beträgt.
  11. Ein Laminat, das Folgendes beinhaltet:
    A) mindestens eine Schicht eines Schaums, beinhaltend:
    (a) ein thermoplastisches Harz, beinhaltend ein Ethylenhomopolymer, ein Ethylen/α-Olefin-Copolymer oder ein Ethylen/α-Olefin-Multiblock-Mischpolymer; ein Polypropylenhomopolymer, ein Propylen/a-Olefin-Copolymer oder ein Propylen/α-Olefin-Multiblock-Mischpolymer; oder Kombinationen davon;
    (b) Wasser;
    (c) ein schäumendes Tensid, beinhaltend mindestens eines von Alkylcelluloseethern, Hydroxyalkylcelluloseethern, Hydroxyalkylalkylcelluloseethern, Guargummi, Xanthan und Polyoxyethylenharzen mit einem Molekulargewicht von mindestens 20 000;
    (d) ein Gas;
    (e) mindestens einen Flammhemmer, beinhaltend mindestens ein Element, ausgewählt aus einem anorganischen Salz, einem Intumeszenzmittel, einer halogenierten Verbindung, einer Phosphatverbindung, einer Boratverbindung, einer Melaminverbindung und Kombinationen davon; und
    (f) ein Dispersionsstabilisierungsmittel;
    wobei der Schaum zu etwa 15 bis 75 Gewichtsprozent Komponente (a), zu etwa 25 bis 75 Gewichtsprozent Komponente (b), zu etwa 0,1 bis 10 Gewichtsprozent Komponente (c), zu etwa 5 bis 50 Gewichtsprozent Komponente (e) beinhaltet, und wobei (d) in einer Menge vorhanden ist, so dass (d) mindestens 10 Prozent des Gesamtvolumens aller in dem Schaum vorhandenen Komponenten ausmacht; und
    wobei der mindestens eine Flammhemmer etwa 5 bis etwa 70 % eines Gesamtgewichts des thermoplastischen Harzes, des mindestens einen schäumenden Tensids und des mindestens einen Flammhemmers ausmacht, und
    (B) mindestens eine Substratschicht, auf der die Schaumschicht (A) aufgebracht wird.
  12. Laminat gemäß Anspruch 11, wobei die mindestens eine Substratschicht aus einer Schicht eines Schaums, einer Schaumstoffschicht, einer thermoplastischen Lage oder Folie, einer Webware oder einem Vliesstoff, Glasfaser oder einem geschmolzenen Spinnmaterial oder einem schmelzgeblasenen Material zubereitet wird.
  13. Eine laminierte Struktur, beinhaltend (a) mindestens eine Schicht des Schaumstoffs gemäß Anspruch 7 und (b) mindestens eine Substratschicht, an der die Schaumstoffschicht (a) angebracht wird.
  14. Laminierte Struktur gemäß Anspruch 13, wobei die mindestens eine Substratschicht aus einer Schicht eines Schaumstoffs, einer thermoplastischen Lage oder Folie, einer Webware oder einem Vliesstoff, Glasfaser oder geschmolzenem Spinnmaterial oder schmelzgeblasenem Material ausgewählt ist.
  15. Laminierte Struktur gemäß Anspruch 13, wobei die Schaumstoffschicht eine Dichte aufweist, die sich von der des Substrats unterscheidet.
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US20130302583A1 (en) 2013-11-14
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US8349920B2 (en) 2013-01-08
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US20100036024A1 (en) 2010-02-11
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